Virgil's process to produce larger, scuptural works has evolved over time. While he sought help and input from other woodturners, he found no one with solutions to crucial challenges like finding tools large and strong enough to shape the objects inside and out, and preventing the splitting and checking of end-grain. Too often, the workshop echoed with the crack of a finished piece as a two-inch rift opened up one side.
Over time, he adapted auto-body and other heavy-duty tools to turn the larger pieces. He also adopted two time-tested solutions for cracking—lubricating the wood for slow drying and using shellac as the final finish. Combined with one high-tech innovation—microwave drying. Given these approaches, he has greatly reduced spoilage.